Technical production method, tension module and sewing material holder for creating textile preforms for the production of fibre-reinforced plastic components

ABSTRACT

Ready-made technical process for manufacturing fiber-reinforced plastic building components that envisions the use of a link and optionally of a flange and/or a base using textile blanks ( 10 ) as starting material, and, initially, at least two layers of the textile blanks are positioned vis-à-vis one another, clamped in and undergo a first sewing-up process, and a preform is fashioned featuring the architecture of the product that is to be manufactured, and subsequently the preform is infiltrated with resin in order to realize the plastic building component, as well as of a tension module for realizing a flange on a textile preform and a sewing material holder that receives a textile preform in order to implement the referred to steps.

[0001] The invention relates to a ready-made technical process formodeling textile preforms for the manufacture of fiber-reinforcedplastic building components using textile blanks as starting material inaccordance with the preambles of the method claims. The inventionfurther relates to a tension module for realizing a flange on a textilepreform as well as a sewing material holder for receiving a textilepreform.

[0002] Cost-efficient textile preforms of reproducible quality areenvisioned for the manufacture of fiber-reinforced plastic buildingcomponents made of textile semi-finished products that approximate, forthe most part, the final contours of the plastic building component(near net shape). The textile preforms are fashioned by way of at leastone clutch, woven fabric or knitted fabric, i.e. generally a textile,two-dimensional architecture. The preforms are used, for example, formanufacturing integrally reinforced planking fields.

[0003] Methods for the quality manufacture of the preforms are knownfrom the general prior art; they involve straight and curvedreinforcement profiles with variable flange, link and base dimensions. Anumber of profile types can be manufactured using these methods.

[0004] The manufacture of fiber-reinforced plastic building componentsfrom textile semi-finished products in accordance with the prior artprovides that said components are, utilizing techniques of the textileindustry, woven, braided, knitted and customized, i.e. cut to size,sewed up and, in a separate processing step, infiltrated with resin forfurther processing. But the minimal component rigidity of braidedstructures, for example, has proved disadvantageous. Moreover, complexstructures with locally arranged thickenings and changeablecross-sectional profile dimensions are difficult to manufacturerequiring extensive manual labor. Reproducibility of constantly reliablequality can only be achieved with much effort and expense. In order tobe able to reproducibly manufacture textile preforms, it is necessary tomake the corresponding arrangements for taking precautions that willprotect the textile handling from irreversible distortions while goingthrough the individual processing steps. The elastic and reversiblepropensity for distortions that textiles possess compromises themodeling processing steps. Consequently, for all operations, it must beensured that the textiles are processed in the absence of any tensileforce acting upon them, i.e. they are manufactured and processed free ofthe influence of external forces.

[0005] The object of the invention consists in providing a ready-madetechnical process that will allow for the production of a large varietyof preforms.

[0006] A further object of the inventions consists in providingapparatuses for implementing the ready-made technical processes thatmake the production of a large variety of preforms possible.

[0007] This object is achieved with the characteristics of theindependent patent claims. Further embodied examples are reflected inthe sub-claims of the former.

[0008] Using the process method according to the invention, it ispossible to manufacture a number of cross-sectional geometries withcurved and straight designs.

[0009] Moreover, reinforcement layers are incorporated in any position;modifications of the cross-sectional dimensions are realized, andreproducible quality of the preforms is guaranteed with this method.

[0010] Technology makes it possible to build three-dimensional preformscomprised of several layers of different textiles, thereby establishingthe elastic and mechanical properties, to incorporate reinforcementlayers at any desired location, to change the cross-sectional dimensionsat any desired position, to create a curve in the longitudinal directionand to reproducibly process two-dimensional textiles intothree-dimensional textile preforms.

[0011] A further advantage of the invention consists in the fact thatpreforms in straight and curved shapes can be manufactured withreproducible quality featuring a number of cross-sectional forms.Another advantage of the invention consists in the fact that it ispossible to realize locally arranged thickenings and changes of thecross-sectional dimensions.

[0012] Subsequently, the invention will be described in more detail byway of the enclosed Figures showing in:

[0013]FIG. 1a, a representation of an embodied example of a textilepreform that can be manufactured in accordance with the method accordingto the invention or of a sub-preform shown from a cross-sectionalperspective and comprising a link and a flange,

[0014]FIG. 1b, a further embodied example of the profile shape thatcomprises, in addition, a base in order to form an LZ-[shaped] profile,

[0015]FIG. 1c, a further embodied example of the profile shape that isrealized as a Z-[shaped] profile,

[0016]FIG. 1d, a further embodied example of the profile shape comprisedof two flanges that are connected to each other by way of a link,

[0017]FIG. 1e, a further embodied example of a profile form comprised ofa link and a base,

[0018]FIG. 2, a schematic depiction of an embodied example in an initialpositioning and sewing direction for the mutual fixing in place of thelayers of the textile semi-finished product in the flange or link area,

[0019]FIG. 3a, a cross-section of an embodied example of the tensionmodule according to the invention,

[0020]FIG. 3b, a schematic perspective-specific representation of a partof an embodied example of the tension module according to the inventionmodeled with a flexible clamping rail and a section of a preform that isclamped into said rod,

[0021]FIG. 4, a schematic perspective-specific representation of anembodied example of a form element and a tension module that is in partapplied to the former, and the tension module is partially applied inorder to realize a lengthwise curve of the preform that is to bemanufactured,

[0022]FIG. 5a, a top view of a tension module that is applied to a formelement,

[0023]FIG. 5b, a perspective-specific detail representation of aclamping rail that is applied to a form element as an embodied exampleof a tension module including a section of a clamped-in preform,

[0024]FIG. 6a, a top view of an embodied example of a sewing frame intowhich a tension module has been inserted, including a holding device,

[0025]FIG. 6b, a section of a further embodied example of a sewing frameinto which the tension module has been inserted, including a holdingdevice,

[0026]FIG. 7, a schematic arrangement of the apparatuses represented inFIG. 5a including stiffening elements in order to support the base areaof the preform,

[0027]FIG. 8a, a cross section of an embodied example of a stiffeningelement for the base area of the preform,

[0028]FIG. 8b, an embodied example of a spacer for modeling the basearea of the preform,

[0029]FIG. 9, a schematic representation of how an embodied example ofthe stiffening element in accordance with FIG. 8a is built,

[0030]FIG. 10, a cross-sectional representation of a sewing materialholder that is envisioned for preforms, which are modeled linearly inthe longitudinal direction, including a tension module and a holdingdevice.

[0031] The method according to the invention is used to manufactureplastic building components that can be curved or straight in theirlongitudinal direction and that can have an angular profile, inparticular, profile shapes as shown in the FIGS. 1a, 1 b, 1 c, 1 d, 1 e.Additional forms can be produced by way of combining the depictedprofile shapes. FIG. 1a shows a profile 1 with a, in terms of the heightextension, first end area or edge area 1 a and a second end area or edgearea 1 b as well as a first end 1 c and a second end 1 d with regard tothe axial or longitudinal direction (not visible in the representationsin FIGS. 1a, 1 b, 1 c 1 d, 1 e). The profile 1 features a link 2 withthe ends 2 a, 2 b and a flange 3 on one of its ends 2 a or 2 b. FIG. 1bshows a profile 4 the link 2 of which also features a flange 3 on itsfirst end 2 a and a base 5 on its second end 2 b. The profile 6 with thelink 2 that is depicted in FIG. 1c features two flanges 3; each of thoseextends horizontally in an opposite direction, respectively, from eitherone of the ends 2 a, 2 b. In the profile 7 in FIG. 1d, the flanges 3extend in the same direction in relation to each other from the link 2.FIG. 1e depicts a profile 8 featuring only a base 5.

[0032] For orientation purposes, a system of coordinates is shown inFIG. 1 that defines the longitudinal direction 9 a or the z-direction ofthe profile 1, its direction of height or y-direction 9 b and itsdirection of width or x-direction 9 c.

[0033] The flanges 3 and bases 5 can extend in a perpendicular directionor in an angular direction from the respective link 2. Thethree-dimensional shape of the final product and/or of the preform thatis used to manufacture the final product determines the two-dimensionalshape of the semi-finished product as well as the course of the seamsthat fasten the layers of the semi-finished products at suitablelocations relative to each other. It is also possible for the productsthat are to be manufactured to extend in bends or curves or in astraight direction.

[0034] The method according to the invention provides that the preformis manufactured from at least two layers of cut-to-size, textile,semi-finished products. These are inserted in a fastening direction(positioning direction) 11, positioned and sewn up in the context of afastening process in order to fix the at least two layers in place forany subsequent draping steps (FIG. 2); [chosen is, in particular], suchan area that represents an area of relatively minimal deformation on thepreform that is to be manufactured. For a preform with a flange or base,an area of this type can be, in particular, the area of the link. Anarea of minimal deformation is an area where re-forming operations willnot cause any changes with respect to the fiber orientation. Localizedreinforcements, if available, are also inserted as part of this step andprovisionally fastened by way of the fastening process. This way, thesemi-finished product becomes a sub-preform or preform 20. A flange 3 isformed by way of a clamping rail (FIGS. 3a and 3 b). To achieve acurving of the semi-finished product in its longitudinal direction, theclamping rail is applied to a modeling arc along with the clamped-insub-preform (FIGS. 4, 5a and 5 b). A base 5 is formed by way of turningapart the edges of a part or the sub-preform 20 along a longitudinalline (FIG. 7). After modeling the preform from a sub-preform, providedthe preform is not already the sub-preform, the pre-form is infiltrated,e.g. in a corresponding mold, with resin in order to obtain the plasticfinal product that is to be manufactured.

[0035] In their respective starting conditions, the textile blanks orsemi-finished products 10 comprise several layers of a textiletwo-dimensional architecture in the form of clutches, knitted fabrics orwoven fabrics. The use of the corresponding textile semi-finishedproducts 10 depends on their draping capacity, i.e. their proneness forincurring deformations of the layers of the preform when distortions andcurves are realized on the latter. The textile semi-finished productmust allow for refashioning it in such a way that in the end positionthere will not result any shifts and/or folds in the material that maynegatively impact its mechanical properties.

[0036] Initially, the textile semi-finished product 10 must be cut intoa shape based upon which it is possible to fashion a preform 20 and,consequently, the plastic final product. Preferably, this preformrepresents the unwound surface of the end product, taking into accountthe effects caused by draping, e.g. making the corresponding allowancesfor draping by planning for additional material. The starting formrepresents layers of a textile semi-finished product used to shape apreform 20 by way of cutting the layers to size and placing them on topof each other and based upon which, for example, the preform that issuitable for the manufacture of the final product is obtained e.g. byway of turning up individual areas of the preform or of areas ofindividual layers or by way of curving in the longitudinal direction.For this purpose, the textile semi-finished product 10 is inserted intoa fastening apparatus 11. In this context, the textile semi-finishedproduct 10 is preferably inserted in such a manner that a longitudinalside 12 extending in the longitudinal direction of the textilesemi-finished product 10 rests against a reference or contact edge 15.The reference or contact edge 15 preferably runs in the longitudinaldirection 9 a of the semi-finished product 10. But it is also possibleto envision multiple reference edges 15, for example, if the textilesemi-finished product 10 has a longitudinal side or edge 12 the courseof which is irregular. The fastening apparatus 11 comprises supportmetals 17 with a sewing window 18 extending in the longitudinaldirection of the semi-finished product and a first support surface 19 alocated between the sewing window 18 and the reference edge 15 as wellas a second support surface 19 b arranged on the opposite side of thesewing window 18. Furthermore, the fastening apparatus 11 can beequipped with one or several clamping devices 16 that fix thesemi-finished product 10 in place in its predetermined position.Preferably, the latter are arranged, either in sections or continuously,along the reference edge.

[0037] The clamping device 16 can also be designed differently thanshown in FIG. 2. The essential aspect is that it satisfies a clampingfunction for the area of the preform. In particular, the clamping device16 can be arranged as detachable on the fastening apparatus 11. For thesubsequent steps, it is also possible to use a tension module 21 that issuitable for use for the present purpose.

[0038] Inside the fastening apparatus 11, the layers of thesemi-finished product 10 are sewn together in relation to each other, inparticular, within the sewing window 18 in accordance with the prior artusing a CNC-controlled double-lockstitch sewing machine and applying atleast one seam 13.

[0039] In order to fashion a sub-preform or a preform 20 on the basis ofthe sewed up semi-finished product 10 that is already more similar tothe end product and/or already approximates said end product and thatwill subsequently be referred to in an abbreviated form as (sub-)preform20 it is possible to remove the sewed up semi-finished product from thefastening apparatus 11 and fit it into a tension module 21. It is alsopossible to use the clamping device 16 for the next steps instead. Usingthe latter is especially advisable if no flange is to be fashioned onthe preform. An alternative method provides that the tension module 21is used in the fastening apparatus 11. In a preferred embodied example,the tension module 16 is comprised of a clamping rail 21 a extending inthe longitudinal direction 9 a of the (sub-)preform 20, the longitudinaldirection of which is designated with the reference symbol 22. Theclamping rail 21 a is also comprised of a contact edge or reference edge23 in order to form a flange area 24; the corresponding side of thesemi-finished product 10, preferably its longitudinal side 12, isapplied to come to rest against that edge. In its capacity as acomponent of the tension module 21, the clamping rail 21 a can compriseseveral holding devices 25 that are arranged along the longitudinaldirection 22, preferably realized as clamping apparatuses or clampingjaws 25, which, in turn, are preferably arranged at regular distancesrelative to one another on a, preferably, flexible clamping rail, orthey are arranged on a spring steel band 26. Preferably, the clampingapparatuses are attached to the spring steel band 26 by way ofconnecting elements or by way of glued connections. In this context,these clamping apparatuses 25 can have a front surface 27 that isdirected toward the link area 2 and a back surface 28. Both surfaces 27,28 are moved relative to each other in order to accomplish a clampingaction of the preform specifically by way of a mechanism (not describedin more detail). The function of the clamping apparatuses 25 consists inholding the (sub-)preform and/or preform 20 in a desired position inrelation to the contact edge 23.

[0040] The tension module 21 is envisioned to form a flange on the endof the preform 20 that is fixed in place by means of the clamping jaws25, which is, as an example, in FIGS. 3a and 3 b the end 1 a. To achievethis, step 30 provides that the sub-preform and/or preform 20 is turnedup by a predetermined line in the longitudinal direction 22 and by apredetermined size of an angle, e.g. a 90 degree angle, in order toapproximate the preform or the (sub-) preform 20 to the shape of theproduct that is to be manufactured, i.e. one of the shapes that arerepresented in the FIGS. 1a to 1 e. The folding or edge line 31 of theflange that is to be formed, resulting due to the turning-up action ofthe edge, depends on the shape of the clamping devices 25 crosswise inrelation to the longitudinal direction 22. The latter extend to the edgeline 31, thereby allowing to achieve the turning-up action 30 to beachieved by way of pressing the areas of the (sub-)preform 20, that restagainst the clamping devices 25, to the e.g. area of the front surface27 of the clamping device 25 that follows and is perpendicularlyarranged in relation to the former.

[0041] The flange formation on a preform, which was describedpreviously, is omitted if the product that is to be manufactured doesnot have a flange. Depending on the product to be manufactured, it ispossible to envision fashioning a base instead.

[0042] Afterwards, the preform 20 is applied against a contact surfaceof a form element 41 in order to support the clamped edge area at thedesired angle.

[0043] If the product that is to be manufactured is to be curved in acertain way in its longitudinal direction 9 a, the tension module 21 isrealized as flexible in the context of a step 40 or a draping process.The preferred embodied example of the tension module 21 with a clampingrail 21 a provides that the latter is realized as flexible in itslongitudinal direction 22, specifically as a spring steel band 26. Inorder to realize a curvature running in the longitudinal direction 22,the tension module 21 is brought to rest against a contact surface of aform element 41, which, in the present case, can be shaped as a modelingarc. The modeling arc 41 comprises a contact surface 42 that features acurvature along its longitudinal direction 42 a corresponding to thepredetermined curvature of the product that is to be manufactured(represented in a exemplary manner in FIG. 5a).

[0044] This step of applying an edge area of the preform to a contactsurface of the form elements is also possible if no flange isenvisioned, but if, for example, a base is envisioned in the edge areathat is located opposite to the clamped area. The latter is particularlyadvantageous in cases in which the goal consists in achieving acurvature in the longitudinal direction 22.

[0045] The form element 41, or also the modeling arc, is depictedschematically, for example, in FIG. 4 in order to show the state thatapplies when draping or applying [step] 40. In the represented embodiedexample, an additional support surface 55 is located below the modelingarc 41 that is arranged at a certain angle relative to the contactsurface 42 in order to achieve a supporting action at this angle and toprevent a slipping away of the (sub-)preform 20 from the desired angularposition. In this context, the support surface 55 features a supportsurface 52 a that is directed toward the preform 20 and upon which theend and/or starting piece of link 2 rests.

[0046] The state in which the clamping rail 21 a is applied to a formelement in the shape of a modeling arc 41 by way of the flexible springsteel band 26 is represented in FIGS. 5a and 5 b. The clamping rail 21 acan be fastened to the modeling arc 41 utilizing fixing or fasteningmeans or in a different way, e.g. by means of a gluing method. In theembodied example that is shown here, the fastening action is achieved byusing the clamping pieces 25 directly on the surface 42 and/or by way ofthe spring steel metal 26 on the surface 42 with the surface that isdirected away from the flange. The fastening action is reversible, forexample, using a Velcro closure.

[0047] The curvature prescribed by the modeling arc 41 requires that thesub-preform 20 is draped in the link area. Subsequently, the draped areamust be fixed in place e.g. by way of a sewing.

[0048] The preform 20 with the first edge area 1 b and the second edgeare 1 b is inserted into a sewing frame or a sewing material holder 52in order to fix the layers of the preform in place by way of sewing themup. The sewing frame 52 is realized in such a way that is able toreceive the preform 20 at the location of a first edge area 1 a alongwith the previously used fastening device and/or tension module 21.

[0049] An embodied example of the sewing frame 52 including a formelement 41 with curved contact surface 42 (compare FIG. 4) is shown inFIG. 6b. A holding device 54 for fixing the edge area 1 b in place thatis arranged opposite to the flange area 3 is located opposite to thetension module 21. The holding device 54 that is envisioned, forexample, on the sewing frame according to the invention can be realizedin various ways, depending on the design form that the edge area 1 b isto take. The embodied example of the holding device 54 in FIG. 6brepresents an embodied example 54 a that allows realizing a base 5 inthe edge area 1 b. Several holding devices 54 intended to realize thebase or fix the link in place are arranged for that purpose along thecurvature (refer to FIG. 6a).

[0050] In the depiction in accordance with FIGS. 6a and 6 b the latteris inserted in conjunction with a tension module 21 including theclamping rail 21 a and the modeling arc into a sewing frame 52 for thepurpose of forming and sewing up the preforms 20 that are curved in alongitudinal direction and equipped with a flange 3. The construction ofthe apparatus depends on the accessibility of the sewing method that isto be employed.

[0051] The embodied example of a sewing frame 52 with several holdingdevices 54 that is depicted in FIG. 6b and is envisioned for use inconnection with preforms that are curved in a longitudinal directioncomprises a first support surface 55, that is identical with the contactsurface or support surface 52 a of the tension module 21 or that acts inconjunction with it and a second support surface 56 with a contactsurface 52 b that is arranged in the second end area 1 b. Thelongitudinal direction 53 a for the preform 20 that is drawn in FIG. 6bcorresponds to the longitudinal direction 9 a in FIG. 1a, thelongitudinal direction 22 and/or 42 a in FIG. 4. The holding devices areseen from the perspective of the longitudinal direction 42 a and/or 53 a[and] preferably arranged at even distances.

[0052] If the product that is to be manufactured is curved in itslongitudinal direction 22, several holding devices 54 are arranged alonga curved longitudinal direction 53 a in FIG. 6a. Step 50 is subsequentlyimplemented in accordance with the step 50 a that is described in FIG.6b.

[0053] If, on the other hand, the product that is to be manufactured isequipped with a base and is not curved in its longitudinal direction 9 aand/or 53 a but linear, the clamping rail 21 is not to be applied to acurved contact surface 42 of the form element 41; the tension module 21is instead realized as linear in its longitudinal direction. In thiscase, it is possible to omit the process step 40. The step 50 forrealizing a base in an edge area of the non-curved preform 20 isimplemented instead of step 50 a, which is described as step 50 b inFIG. 10a. A corresponding embodied example of the sewing frame 82 isrepresented in the FIGS. 10a and 10 b.

[0054] In the alternative, both the sewing frame 54 and the sewing frame82 can be realized in such a way that no holding devices 54 are arrangedor possible to insert for the purpose of forming a base in the edge area1 b. Depending on the architecture of the preforms 20 that are tofashioned, it is also possible to envision a tension module 21, afastening device 16 or a different kind of clamping apparatus on thesewing frame 52 and/or the sewing frame 87 for holding or clamping theedge area 1 b.

[0055] The extension of the sewing material holder or sewing frame 52and/or 82 in its direction of width 53 b is realized in such a way that,in this direction, the (sub-) preform 20 is circumgripped. The sewingframe 52 and/or 8[2] that is displayed in FIG. 6b and/or 10 a can haveits own, i.e. installed as stationary or integrated, form element 41 andclamping rail 21 including clamping devices 25. Advantageously, however,the form element 41 and the clamping devices 25 are arranged on thesewing frame 52 as exchangeable or with the ability to be inserted; andthe form element is taken from one of the previous steps, e.g. thedraping step 40. This means that the sewing frame 52 is realized in sucha way that it is possible to insert the tension module 21 with the(sub-) preform 20 and that it can be optionally fastened.

[0056] If no flange is to be realized in the edge area 1 a of thepreform 20, it is possible to envision that the tension module 21 oranother clamping apparatus, e.g. the clamping device 16, be inserted inthe sewing frame 52 and/or the sewing frame 87; and, in this instance,the clamped-in edge area 1 a is, for example, not turned up but extendslinearly.

[0057] The sewing frame 52 in accordance with FIG. 6b for curved, i.e.draped preforms 20, comprises at least one sewing window 57 that isarranged between the support surfaces 52 a and 52 b and extends in thelongitudinal direction 22 and/or 42. It is also possible to envisionseveral windows 57 that are arranged along the longitudinal direction 53a. The sewing frame 52 including the windows 57 is used to fasten the(sub-)preform 20 in terms of its architecture in accordance with thesteps 30 and/or step 40 inserting the seams 60. By applying at least oneseam or a dense series of seams to the (sub-)preform 20, the link area 2is fixed in terms of its shape in order to improve the properties of thebuilding component for withstanding damage. When step 40 is implemented,the curvature of the (sub-) preform 20 is also fixed in place by way ofseveral seams 60. The seams 60 are applied using sewing machinesaccording to the state of the art, e.g. portal or robotic sewingmachines (not shown). Incorporating the seams 60, which can be donepartially or across planes, can also be achieved in such a manner thatthe seams improve the in-plane properties, i.e. the mechanicalproperties to withstand delamination and the properties to toleratedamag[ing influences].

[0058] To realize a base 5 in the edge area 1 b, during step 50, aspacer or hollow space filler or, preferably, a gusset 65 (FIG. 8b) canbe incorporated between the corresponding layers 63 a, 63 b of the(sub-)preform 20, [in particular,] in the longitudinal direction 42 awhich is in the longitudinal direction of the base or extending inaccordance with the course of the fold. Preferably, this is done whilethe preform 20 is located inside the sewing material holder 52 and/or82. A preferably envisioned gusset 65 is depicted in FIG. 8b. Dependingon its application, it is also possible to design the spacerdifferently, in particular in terms of the shape of its cross section.The essential aspect [for the spacer] consists in the fact that thespacer can be inserted between the layers of the preform 20 and that itkeeps the respective layers apart. Preferably, the spacer is realized insuch a way that it is able to receive a fastening seam. The preferredcross section of the gusset 65 is approximately triangular (FIG. 8b),and it comprises a tip 65 a, which is directed toward window 57 once thegusset 65 has been inserted in the (sub-)preform 20, as well as a bluntend 65 b arranged opposite to the former end.

[0059] The axial ends 65 c, 65 d are arranged, preferably, in the areaof the axial ends 1 c and/or 1 d of the (sub-)preform 20, provided thespacer or gusset 65 has been inserted into the latter. In order toachieve the corresponding positioning of the spacer or the gusset 65, acontact seam or contour seam 66 is applied to the (sub-)preform 20 atthe location of the edge of the window 57 that is located in closeproximity to the end area 1 b. Afterwards, the gusset 65 can be pushedin the direction of the tension module 21 and/or the first edge area 1 aof the (sub-)preform 20 until the tip 65 a of the gusset 65 pointing inthat direction makes approximate contact with the contour seam 66. Inthis context, the contour seam 66 defines the geometry of the baseand/or the height of the link 2 and/or the edge line 91 (refer to FIG.1e) of the base 5. Based on the selection of the contour seam 66, it ispossible to realize variable link heights. If the (sub-)preform 20 iscurved in the longitudinal direction 9 a, i.e. if the clamping rail 21 ais curved and applied to a modeling arc 41(step 40), the gusset 65 isadvantageously positioning by way of applying a minimal tensile force onthe spacer or gusset 65, [in particular] at its lengthwise ends 65 c, 65d (not shown here). It is possible to envision a mechanism for thepurpose of applying counteracting tensile force in the longitudinaldirection. Due to the curvature of the gusset 65, said gusset is thuspulled in the direction of the contact seam or contour seam. The gusset65 is afterwards fixed in place within the corresponding layers of the(sub-) preform 20 by way of inserting a fastening seam 67 that runsparallel relative to the contour seam 66. The fastening seam 67 ispreferably arranged in the area of the tip 65 a of the gusset 65. Toinsert the gusset, the second end area 1 b, for which the realization ofthe base 5 is envisioned, is folded open, and the corresponding layerand/or corresponding layers of the (sub-)preform 20 are lifted off theremaining layers of the (sub-)preform 20.

[0060] In further steps, a sewing process is carried out in order to fixthe layers or the draped link areas into place and, if necessary, thoseof other areas of the preform 20. Corresponding areas of layers aresubsequently folded apart in opposite directions in order to realize abase 5. If required, depending on a case by case basis, these areas areequipped with stiffening elements in order to achieve a mechanicalstabilization of the base.

[0061] For purposes of equalizing an uneven course of the contour in thesecond end area or in the base area 1 b, the holding device 54 ispreferably realized to include a press-on means intended to press thespacer 65 against the contact seam 66. It is preferred that the press-onmeans is comprised of at least one push metal 69 with an impact surface69 a, which pushes, utilizing an adjustment mechanism 72, the gusset 65against the gusset contact seam or the contour seam 66, thereby ensuringthe positioning of the latter. In the longitudinal direction 53 a, pushmetals 69 are to be envisioned, preferably, especially in those placeswhere the height of the link 2 is locally reduced, which means that acontact of the gusset 65 with the gusset contact seam 66 is notguaranteed in these locations. Each push metal 69 is equipped with animpact surface 69 a that rests against the blunt end 65 b of the gusset65, which is why the push metal is preferably arranged at an angle inrelation to the support surface 52 b. An end piece 69 c of the pushmetal 69, that is located in the edge area, is shaped in such a way thatit allows for the engagement of a tension element 71 of the holdingdevice 54 in order to press the push metal 69 along with the gusset 65against the contour seam 66. A mechanism 72 according to the state ofthe art (not shown here) is connected to the transfer element 71; and it[effects] that the pushing movement of the push metal 69 and its holdingaction in the final position [is maintained], when the gusset 65 restsagainst the contour seam 66. The holding device 54 is further comprisedof the suppression metal 73, for example, a metal block with the hingefor folding down the suppression metal, preferably arranged on themechanism 72. The suppression metal 73 is positioned in such a way thata corresponding surface 73 a of the second end area 1 b of the(sub-)preform 20 presses against the support surface 52 b of the supportmetal 56. The purpose of the suppression [metal] consists in fixing thepreform 20 in place so it can withstand the forces that are generatedduring the sewing process.

[0062]FIG. 10a represents the method step 50 b for realizing a base 5,for instance, when the product that is to be manufactured is not curvedin its longitudinal direction 9 a and the draping process 40 is,therefore, omitted. The sewing frame or sewing material holder 52 iscorrespondingly designed as linear in its longitudinal direction 53 a. Asection of sewing frame 82 and an embodied example 54 b of holdingdevice 54 is shown in FIG. 10a for a step 50 b, and, in this case shownthere, the preform features a flange in the edge area 1 a. The spacer 66[has the properties] as depicted as in FIG. 6b. A contact seam 66 isalso envisioned. Moreover, the sewing material holder 82 that isdepicted is also comprised of at least one window or sewing window 87;this is the area where the seams 60 are inserted into the (sub-)preform20 that is placed onto sewing frame 82 in order to fix the layers of(sub-)preform 20 in place. The sewing material holder 82 has a firstedge area 82 a that rests against the tension module 21 as well as asecond edge area 82 b. The contour seam 66 determines the contour of thelink 2 and/or the course of the base of the profile that is to beproduced or of the edge lines 91 of the latter, because it correspondsapproximately to said course that the base areas follow when extend awayfrom the link area.

[0063] The spacer or gusset 65 is introduced between two layers. Topress the spacer or gusset 65 against the contour seam 66, the secondend area or base area 1 b of the (sub-)preform is separated by layers,as shown schematically in FIG. 10a. The edge areas of two textile layers63 a, 63 b are folded apart in opposite directions vis-à-vis each otherduring this process. Due to the lack of a curvature in the longitudinaldirection, it is advantageous to apply a tensile force to the spacer orgusset 65 in order to guide [it] close enough to the contour seam 66. Toinsure the exact positioning of the gusset for step 50 b, it is,furthermore, possible to envision a press-on means used to move and fixthe spacer in place and to integrate it with the holding device. Theembodied example shown in FIG. 10a provides for using a needle bar 88with needles 88 a that can be moved by way of the adjustment mechanism74 and for a feed means that is realized as a comb metal 89. The spacer65 is placed on the needle bar 88, which is guided by way of the combmetal 89, and fixed in place utilizing the needles 88 a of the needlebar 88 (FIG. 10b). The blunt surface 65 b of the gusset that isenvisioned rests, if necessary, correspondingly against the surface 89 cof the comb metal 89. Several needle bars 88 can be envisioned along thelengthwise extension 53 a of the holding device 54 in order to modifythe widths with regard to the link [areas]. The needle bar 88 holds thegusset 65 in its longitudinal direction in a predetermined and, inparticular, linear form. The comb metal 89 pushes against the gusset 65,the shape of which is maintained by the needle bar 88, thereby pressingit against the contour seam 66. The gusset can then be fixed in placeutilizing a fastening seam 67; however, to prevent collisions betweenthe needles 88 a of the needle bar 88 with the sewing needle of thesewing machine, it is necessary that the needle bar 88 be moved in thedirection of the width. Due to the pressure applied by the comb metal 89and the textile layers 63 a and 63 b of the base area, the gusset 65 issufficiently fixed in place.

[0064] If, for example, the goal consisted in producing profiles asshown in FIG. 1b and FIG. 1f, it is necessary to shape the base area inthe context of a further method step 60 and to fix the free edge areasor base areas of the respective layers in place. Advantageously,additional stiffening layers or a stiffening element 91 (FIG. 8a) areincorporated in the base area 5.

[0065] Step 60 for the stiffening of base area 1 b provides that,irrespective of whether there is a curve in the longitudinal directionor not, the tension module 21 is brought into a corresponding positionthat allows free access to base area 1 b in order to realize a base 5.For this purpose, the tension module 21 is removed from the sewing frame52. The link area 2 of the (sub-)preform 20 is supported by the supportelements 93 (FIG. 7), i.e. it is maintained as a plane architecture inits predetermined form. Simultaneously, the support elements 93 serve asassembly aids for the, at least one, stiffening element 91.

[0066] The free ends or edge areas of the bases can be arranged at anydesired angle relative to one another or with regard to the link area;and they can be stiffened, for example, by employing stiffeningelements.

[0067] The envisioned stiffening layers 91 are advantageously comprisedof several layers featuring a regular or constant course of the edgecontour. Used as starting materials are, for example, multi-axialclutches and narrow-wide fabrics 91 a that are adjusted to the requiredarchitecture of the base 5 of the profile that is to be manufactured.The components of the stiffening layers are preferably connected to oneanother by way of sewing or gluing, using thermoplastic fibrous webmaterial or using thermoplastic yarns that are already part of thefabric and that are melted together.

[0068] When sewing, all blanks of the stiffening layers 91 a arepositioned in the sewing apparatus or a sewing frame and combined by wayof one or multiple seams. If bonding agents are used, the blanks offabrics 91 a and/or clutches 91 b are positioned on a substrate (FIG.9). In this context, it is possible to apply, in addition, athermoplastic fibrous web 91 c, following piling, on top of thestiffening layers 91 a and 91 b. The stiffening layers are subsequentlyexposed to heat and pressure, resulting in the melting of thethermoplastic material. After cool-down, all layers 91 a are gluedtogether. The thermoplastic fibrous web 91 c is used as a fasteningmaterial for the assembly of the layers or fabrics 91 a, which are sewntogether, in the base area 1 of the (sub-)preform 20.

[0069] The at least one stiffening element 91 is positioned in the basearea 1 b, in particular, in such a way that the free ends 1 e, 1 f ofthe base area that are folded apart by layers form, in conjunction withthe link area 2, a base of a predetermined architecture. Depending onthe respective application, the latter can point away from the link atany desired angle, e.g. at a right angle. The at least one stiffeningelement 91 is placed onto the end area 1 g, which is formed by the freeends 1 e, 1 f, and is preferably glued together by way of a thermaltreatment or mechanically sewn together. In order to position thestiffening layers for subsequent steps in the base area 5, saidstiffening layers are held by means of a positioning metal 94. Theexecution of the positioning metal 94 depends on the type of theassembly. If the at least one stiffening element 91 is equipped with afibrous web 91 c, the latter is melted [onto the element] during aheating process and utilized for combining the components. Therefore,the fibrous web should be arranged in the assembly area of the base area5.

[0070] The preform is removed from the tension module 21 after thestiffening elements 91 have been installed. For further processing, thepreform is positioned inside an infiltration tool and wetted with resinin accordance with methods that are known in the art. In this context,it is possible to envision the previously described apparatuses or othersupport elements for supporting the areas of the preform.

1. Ready-made technical process for manufacturing fiber-reinforcedplastic building components comprised of a link and at least one flangethat extends in the longitudinal direction using textile blanks (10) asstarting material including the steps of: the positioning vis-à-vis oneanother, clamping in and initial sewing-up of at least two layers oftextile blanks in order to fix the former into place relative to oneanother for the purpose of realizing a preform, infiltrating the preformwith resin for the purpose of manufacturing the plastic buildingcomponent, wherein, following the initial sewing-up of the textilepreforms, an end area (1 a) of the at least two layers that extend inthe longitudinal direction is turned up (step 30) by a predeterminedangle in order to create the flange, the turned up edge area is applied(step 40) to a linearly extending contact surface (42) of a form element(41), the link area (2) is fixed in place relative to the turned up edgearea in a sewing material holder (52) and the layers are sewed up in atleast one of the sewing windows (87) envisioned in the sewing materialholder (52).
 2. Ready-made technical process for manufacturingfiber-reinforced plastic building components comprised of a link and atleast one flange that extends in the longitudinal direction as claimedin claim 1 wherein the same clamping apparatus (21) is used for clampingin the two layers in order to fix them in place and for turning up thepreform (20).
 3. Ready-made technical process for manufacturingfiber-reinforced plastic building components comprised of a link and atleast one base that extends linearly in the longitudinal direction usingtextile blanks (10) as starting material wherein these steps arefollowed: the positioning vis-à-vis one another, clamping in and initialsewing-up of at least two layers of textile blanks in order to fix theformer into place relative to one another for the purpose of realizing apreform, infiltrating the preform with resin for the purpose ofmanufacturing the plastic building component, wherein, following theinitial sewing-up of the textile performs, a contour seam (66) isinserted along the end area (1 b) of the preform (step 50 b), and thefree edge areas (1 b) comprised of at least two layers are turned up ata predetermined angle in order to realize the course of the base that isto be created, a spacer (65) extending in a longitudinal direction ofthe contour seam (66) is inserted between two layers, the two layers aresewed up in at least one sewing window (87) envisioned in the sewingmaterial holder (52), the free end area (1 b) of the base that is to becreated is fixed in place by way of stiffening elements (91). 4.Ready-made technical process for manufacturing fiber-reinforced plasticbuilding components comprised of a link and at least one base thatextends linearly in the longitudinal direction as claimed in claim 3wherein a fastening seam (67) is inserted in the at least two layers inorder to fix the spacer (65) in place.
 5. Ready-made technical processfor manufacturing fiber-reinforced plastic building components comprisedof a link and at least one base that extends linearly in thelongitudinal direction as claimed in claim 3 or claim 4 wherein thespacer (67) is pressed against the contour seam (66) by way of apress-on means.
 6. Ready-made technical process for manufacturingfiber-reinforced plastic building components comprised of a link and atleast one base that extends linearly in the longitudinal direction asclaimed in claim 3, 4 or 5 wherein a flange is realized on another endarea (1 a) by way of clamping in and turning up (step 30) the end area(1 a) extending in the longitudinal direction of the at least two layersby a predetermined angle in order to realize the flange, the turned upedge area is applied against (step 40) a linearly extending contact area(42) of a form element (41), the link area (2) is fixed in placerelative to the turned up edge area inside the sewing material holder(52) and the layers are sewed up in at least one sewing window (87)envisioned in the sewing material holder (52).
 7. Ready-made technicalprocess for manufacturing fiber-reinforced plastic building componentscomprised of a link and at least one flange that is curved in thelongitudinal direction using textile blanks (10) as starting materialincluding the steps of: the positioning vis-à-vis one another of atleast two layers of textile semi-finished products, clamping in andsewing-up of said layers in order to fix the former into place relativeto one another for the purpose of realizing a preform (20), infiltratingthe preform (20) with resin for the purpose of manufacturing the plasticbuilding component, wherein, in order to realize the flange (3), an edgearea (1 a) of the preform (20) is clamped into a tension module (21)that is flexible in its longitudinal direction and the edge area (1 a)of the preform (20) is turned up by a predetermined angle and thetension module (21) is applied (40) with the turned up edge area to thecurved contact surface (42) of a form element (41), the preform (20) isinserted into a sewing material holder (52), the link area (3) is drapedin order to realize the curvature in the longitudinal direction and thepreform (20) is fixed in place by way of inserting the seams (60). 8.Ready-made technical process for manufacturing fiber-reinforced plasticbuilding components comprised of a link and at least one flange that iscurved in the longitudinal direction as claimed in claim 7 wherein thesame clamping apparatus (21) is used for clamping in the two layers inorder to fix them in place and for turning up the preform (20). 9.Ready-made technical process for manufacturing fiber-reinforced plasticbuilding components comprised of a link and at least one flange that iscurved in the longitudinal direction as claimed in claim 7 or claim 8wherein, in order to realize a base vis-à-vis the flange area, followingthe initial sewing-up of the preform, a contour seam (66) is insertedalong an end area (1 b) of the preform (step 50 b) and the free edgeareas (1 b) of at least two layers are turned up by a predeterminedangle in order to realize the course of the base (5) that is to becreated.
 10. Ready-made technical process for manufacturingfiber-reinforced plastic building components comprised of a link and atleast one flange that is curved in the longitudinal direction usingtextile blanks (10) as starting material including the steps of: thepositioning vis-à-vis one another, clamping in and initial sewing-up ofat least two layers of textile blanks in order to fix the former intoplace relative to one another for the purpose of realizing a preform(20), infiltrating the preform with resin for the purpose ofmanufacturing the plastic building component, wherein the preform (20)is inserted into a sewing material holder (52), the link area (3) isdraped in order to realize the curvature in the longitudinal directionand the preform (20) is fixed in place by way of inserting the seams(60). following the initial sewing-up of the textile performs, a contourseam (66) is inserted along the end area (1 b) of the preform (step 50b), and the free edges areas (1 b) comprised of at least two layers areturned up at a predetermined angle in order to realize the course of thebase (5) that is to be created, a sewing process is implemented in orderto sew up the layers inside a sewing window (87) envisioned in thesewing material holder (52), the free end area (1 b) of the base that isto be created is fixed in place by way of stiffening elements (91). 11.Ready-made technical process for manufacturing fiber-reinforced plasticbuilding components comprised of a link and at least one flange that iscurved in the longitudinal direction as claimed in claim 10 wherein aspacer (65) is inserted between the layers of the preform (20) in thearea of the base (5) that is to be created after the preform (20) hasbeen inserted in a sewing material holder (52) and a fastening seam (67)is inserted in order to fix the spacer in place on the preform (20). 12.Ready-made technical process for manufacturing fiber-reinforced plasticbuilding components comprised of a link and at least one flange that iscurved in the longitudinal direction as claimed in claim 10 or claim 11wherein in order to realize the flange (3), an edge area (1 a) of thepreform (20) is clamped into a tension module (21) that is flexible inits longitudinal direction and the edge area (1 a) of the preform (20)is turned up by a predetermined angle and the tension module (21) isapplied (40) with the turned up edge area to the curved contact surface(42) of a form element (41).
 13. Tension module 21 for realizing aflange on a textile preform for manufacturing fiber-reinforced plasticbuilding components wherein the tension module 21 is comprised of aflexible clamping rail (21 a) and several champing jaws (25) that arearranged in the longitudinal direction (22) of the clamping rail inorder to clamp in the area of the flange (3) that is to created. 14.Sewing material holder (52) for receiving a textile preform (20) for themanufacture of a fiber-reinforced plastic building component wherein thesewing material holder (52) is comprised of a first (55) and of a second(56) support surface for receiving the preform (20), a holding device(54) on the second (56) support surface for fixing a second edge area ofthe preform (20) in place, a tension module (21) for clamping in thepreform (20) with a first edge area (1 a), at least one sewing window(57) that is arranged between the support surfaces (55, 56) in order tofix the layers of the preform in place by way of the seams (60). 15.Sewing material holder (52) for realizing a base that extends linearlyin its longitudinal direction on the textile preform (20) formanufacturing a fiber-reinforced plastic building component as claimedin claim sda wherein the holding device (54), in order to press on aspacer (67) to be applied between two layers, comprises a contour seam(66) inserted on the spacer, a needle bar (88) and a comb metal (89),acting in conjunction with the latter and that is movable by way of anadjusting mechanism (74).
 16. Sewing material holder (52) for realizinga base that is curved in its longitudinal direction on the textilepreform (20) for manufacturing fiber-reinforced plastic buildingcomponents as claimed in claim 15 wherein the holding apparatus (54), inorder to press on a spacer (67) to be applied between two layers,comprises a contour seam (66) inserted on the spacer, a needle bar (88)and a push metal (69, 69 a), acting in conjunction with the latter andthat is movable by way of an adjusting mechanism (74).